Redundant tire and rubber compound reprocessing

ABSTRACT

The invention provides for methods, systems, and devices for processing rubber materials including rubber from tires, tubes, shoe soles, or any other rubber containing product. Characteristics of the rubber materials, such as chemical composition and/or product manufacturer, model, and manufacture date, can be identified. Identification can be performed by personnel, can be automated, or can be a combination thereof. The characteristics of the rubber material can be used to sort the rubber product. Rubber materials suitable for a particular end product can be selected for further processing, which can include size reduction, material separation, chemical and physical processes, devulcanization, or a combination thereof. Processed rubber materials can be stored or delivered to a user or manufacturing site with product specifications.

CROSS-REFERENCE

This application is a continuation application of U.S. patentapplication Ser. No. 12/628,947, filed on Dec. 1, 2009, which is acontinuation-in-part application of U.S. patent application Ser. No.12/476,211 filed on Jun. 1, 2009, which claims the benefit of priorityto U.S. Provisional Patent Application Ser. No. 61/058,122 filed on Jun.2, 2008, which are incorporated by reference herein in their entirety,and to which applications we claim priority.

BACKGROUND OF THE INVENTION

Automotive tires and other rubber products are often difficult todispose. Further, many recycling procedures have been proposed or are inuse to handle these rubber materials. However, most of these proceduresprovide an end product that is lower in quality than the original rubbermaterial. As such, much of the recycled rubber is used for alternativeuses, such as playground floors, running tracks, and various padding orrubber structures or devices.

It would be a significant advance in the art if a recycling process forwaste rubber, such as old automotive tires, provided an end producthaving a defined composition and capable of being used to manufacturenew products demanding very good rubber quality. For example, it isdesirable in the art to develop a process that can recycle usedautomotive tires for the partial manufacture of new automotive tires.The objective of delivering high quality rubber end products fromrecycled rubber has proven difficult, however, the processes describedherein provide a novel approach to manufacturing high quality productsfrom recycled rubber.

SUMMARY OF THE INVENTION

The invention provides for methods, systems, and devices for processingrubber materials including rubber from tires, tubes, shoe soles, or anyother rubber containing product. Characteristics of the rubbermaterials, such as chemical composition and/or product manufacturer,model, and manufacture date, can be identified. Identification can beperformed by personnel, can be automated, or can be a combinationthereof. The characteristics of the rubber material can be used to sortthe rubber product. Rubber materials suitable for a particular endproduct can be selected for further processing, which can include sizereduction, material separation, chemical and physical processes,devulcanization, or a combination thereof. Processed rubber materialscan be stored or delivered to a user or manufacturing site with productspecifications.

The personnel for identifying the input materials and/or overseeing theprocess can be trained to follow regulatory standards and/or any otherstandards. The personnel can be trained to identify the composition ofthe input material using any of a number of analytical techniques. Theanalytical techniques can be any analytical technique known to oneskilled in the art.

The rubber materials can be processed such that contaminants, toxicmaterials, metal, or any other undesirable material is removed. Therubber materials can be processed such that the processed rubber productcan be used in a selected process or for a selected product. In someembodiments of the invention, the rubber is processed such that theproduct will meet selected specifications. These specifications caninclude size, composition, mechanical properties, or any othercharacteristic described herein.

Equipment used to process the rubber materials can include rotaryshears, conveyors, troughed out feed conveyors, dividing chutes,dividing conveyors, pre-shredders, magnetic tables, granulators,overband magnets, elevating conveyors, zig zags, cyclones, grids, andmeshes. Other equipment used to process the rubber materials, describedherein or known to one skilled in the art, can be used to process rubbermaterials.

INCORPORATION BY REFERENCE

All publications and patent applications mentioned in this specificationare herein incorporated by reference to the same extent as if eachindividual publication or patent application was specifically andindividually indicated to be incorporated by reference.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features of the invention are set forth with particularity inthe appended claims. A better understanding of the features andadvantages of the present invention will be obtained by reference to thefollowing detailed description that sets forth illustrative embodiments,in which the principles of the invention are utilized, and theaccompanying drawings of which:

FIG. 1 demonstrates assessment and selection procedures formanufacturing new products from recycled rubber.

FIG. 2 illustrates a high-level depiction of a controlled processingsystem in accordance with an embodiment of the invention.

FIGS. 3A, 3B, 3C, and 3D demonstrate an exemplary system wherein afterraw material, such as waste or redundant rubber, is selected by aprocess of the invention carried out by trained personnel, the specifiedraw material is delivered and loaded for a first shredding process. Thebottom of FIG. 3A continues at the top of FIG. 3B. The bottom of FIG. 3Bcontinues at the top of FIG. 3C. The bottom of FIG. 3C continues at thetop of FIG. 3D.

DETAILED DESCRIPTION OF THE INVENTION

Methods and processes are described herein that are useful in generatingobjects from redundant or recycled rubber, such as material to besubstituted for new rubber and/or used rubber in the manufacture oftires. In an aspect, a process comprises: assessing redundant tiresand/or waste rubber materials according to a compound formulae of thewaste materials; and selecting materials to be separated from the wastematerials, wherein the material is selected for the manufacture of anobject; and separating the selected tires and/or waste rubber materials,wherein said separation is for processing the separated material for theparticular end uses predetermined for the specific qualities of theselected redundant tires. This process may be undertaken in a novel wayusing electronic identification systems that select the tire inaccordance with its known composition.

The processes and systems described herein may require significantlyless energy, such as heat energy, cooling, and the addition of chemicalsto generate a recycled rubber material than current methods of rubberrecycling. In an embodiment, the processes and systems can reduce acarbon footprint and improve the sustainability of a rubber recyclingmethod.

In an embodiment, after the waste materials have been assessed, selectedand separated, two types of waste materials or more may be mixed toachieve an end product formula according to an end user. In a furtherembodiment, the mixing can be monitored within the controls incorporatedwithin the process to regulate and manage the end product production.

Personnel

In an embodiment, persons carrying out the duties of assessment andselection must have completed bespoke training courses that qualifiesthe operatives to be fully aware of the methods and process ofselection. These training courses may be internationally recognized. Thepersons may also be aware of the adverse consequences of non compliancewith laid down selection procedures. Additional process security can becarried out by inspectors exercising continuous audit of the selectionprocedures through sample inspections.

The assessment and selection process may be carried out in any approvedand endorsed work suitable location so long as the selected productscannot then be interfered with prior to processing the products ormaterials carried out in the controlled environment within the processplant. In an embodiment, the suitable location is approved by a personwith training in a process of the invention.

In an embodiment, a properly trained person performs the assessment andselection functions for quality control of the selection of theredundant materials. In another embodiment, the functions are performedby computer system based on criteria or input from or associated withthe product itself. The process may have ISO process adherence.Personnel for performing functions described herein or for controlling acomputer system for performing the functions can be trained, tested, andrepeatedly examined to assure high quality control of the process thatcan often be important to many of the processes described herein.Personnel can also be provided consistent updates based on productdetails or changes in products.

In an exemplary embodiment, personnel for carrying out a process orselection process of the invention are trained to assess the redundant,recycled, or waste material based on a plurality of characteristics ofthe material. For example, the characteristics can include, but are notlimited to, material type (for example, make and size), extraction ofmetal, wire or fiber from the material, process size, shape and granuletype for a specific end application of the processed material, mixes ofdifferent characteristic process materials for an end application, andprocess volume and weight. After the initial assessment, all processesnecessary to generate a new product or end application can be monitoredby personnel or a computer system for the date and time of the process,the volume of the processed material, or any other item that may bedesired regarding the characteristics of the final processed materialfor use in an end application.

The necessary processes may be determined by personnel and/or anautomated system based on the desired end applications or products. Forexample, given a waste rubber material, trained personnel may determineperformance characteristics for processing equipment. The processingequipment may be variable and programmable. For example, the speed ofoperation, speed of rotation, speed of conveyance, time, temperatures,strength, amount of power, treatment chemicals, and/or any otherperformance characteristic of an item of processing equipment may bevaried (e.g., increased/decreased) and/or maintained to yield thedesired end application or products. Processing equipment may includeany of the devices and/or apparatuses described herein, including butnot limited to rotary shears, conveyors, troughed out feed conveyors,dividing chutes, dividing conveyors, pre-shredders, magnetic tables,granulators, overband magnets, elevating conveyors, zig zags, cyclones,grids, and meshes. In some alternate embodiments, an automated system,such as a computer system, may determine performance characteristics forone or more processing equipment based on the waste rubber materialsreceived and/or the desired characteristics for the end product.

In some embodiments, personnel may be provided with and/or interactingwith a set of controls that may enable the personnel to perform theassessment or selection functions and/or carry out any of the stepsdescribed herein. The controls may be provided as any user interactiveinterface including but not limited to a computer interface, one or morescreens, buttons, knobs, switches, levers, or any other set ofinterfacing devices. A user interactive interface may be configured toreceive input from trained personnel. Such input may include but is notlimited to input relating to sorting, material characteristics, materialidentification, identification or characteristics of desired endproducts, or processing equipment performance characteristics.

Input Materials and Identification

From the time that the redundant tire and rubber compound materials comeinto the control of the process regulations, the selected batches andthe material that proves not fit for process can be identified withtraceable tags or other devices that move with the batches through theprocess system until the end product is packed ready for use orshipment. In an embodiment, all of the end products carry clear andconcise traceability tags with the constituent make-up formulae labelsto describe the content. For example, the end products may be bar coded,RFID-tagged, or have other electronically identifiable devices. The tagsmay identify the batch and/or materials and said identifiers may becross-referenced or provide access to a database or any other set ofrecords that may have additional information about the materials. Suchadditional information may include information about materialcharacteristics, age, features, intended end product, characteristics ofan intended end product, and/or equipment performance parameters.Alternatively, the tags themselves may contain information about thebatch and/or materials, which may or may not include the additionalinformation discussed herein.

As a result of a recycling process providing a clear definition of theend product composition, the end products may be recycled again andrepeatedly. For example, tracked recycled materials can be known andunderstood for the end use applications for which the materials aresuited, which may also avoid or minimize material failure and health andsafety issues. In another example, a process may require theidentification of the composition of every tire manufactured forrecycling to more easily and accurately control. A rubber material canbe composed of a variety of components, including isoprene, sulfur,ebonite, 3-methylisoprene (2,3-dimethyl-1,3-butadiene), thiokol,divinylacetylene, neoprene, isobutylene (2-methylpropene), styrenebutadiene rubber (SBR), acrylonitrile-butadiene rubber (NBR),cis-1,2-polyisoprene, cis-1,4-polybutadiene, polyurethane,ethylene-propylene terpolymer rubber (EPDM), metal, steel, pigment, andcarbon black. Additional components can be found in U.S. Pat. Nos.4,240,587, 5,157,176, 5,236,992, 5,375,775, 5,634,599, 5,883,139,6,407,180, and 6752940, each of which are incorporated herein byreference in their entirety. Table I lists a variety of components thatcan be identified in various rubber compositions. Table II lists avariety of components that can be identified in redundant tires used fortrucks and passenger cars in the European Union and Tire rubber fromCanada. Approximately 80% of the weight of car tires and 75% of trucktires can be rubber compound. In some instances, the compositions oftires produced by different manufacturers can be similar or dissimilar.Tires can contain approximately 1.5% by weight of hazardous wastecompounds, as shown in Table III. These compounds can be encased in therubber compound or present as an alloying element. Any of thesecomponents can be identified by personnel or by automated processes andused to identify a rubber material to be processed, to identify aselected end product, used to separate the rubber material duringprocessing, or used as a criteria for separation of the rubber materialduring processing.

TABLE I Composition A: Composition B: Composition C: SBR Rubber EPDMRubber SBR Rubber SBR EPDM SBR 1712 N-330 Carbon N-330 Carbon CIS-1,4 BRBlack Black Carbon Black Sundex 790 Plasticizing Agent Oil (Sundex 790)Plasticizing Agent Flexon 766 Zinc Oxide Zinc Oxide Zinc Oxide SunproofImproved Stabilizer Stearic Oxide Stearic Oxide Wingstay 100 AntioxidantAntioxidant Stearic Acid Santocure Santocure N-cyclohexyl-2- TMTD TMTDbenzothiazolesulfenamide Sulfur Sulfur 2-mercaptobenzothiazole Sulfur

TABLE II Car Tires Truck Tires Tire Rubber Material (EU) (EU) (Canada)Rubber/elastomers  47% 45% 62%  Carbon black 21.5% 22% 31%  Metal 16.5%25% NA Fibre  5.5% — NA Zinc oxide   1%  2% 2% Sulfur   1%  1% 1%Additives  7.5%  5% 4%

TABLE III Chemical Name Remarks Content Copper compounds Alloyingconstituent of metallic Approxi- reinforcing material mately 0.02% Zinccompounds Zinc oxide, retained in the rubber Approxi- matrix mately 1%Cadmium On trace levels, as cadmium Maximum compounds attendantsubstance of 0.001% the zinc oxide Lead or Lead On trace levels, asattendant Maximum compounds substance of the zinc oxide 0.005% Acidicsolutions or Stearic acid, in solid form Approxi- acids in solid formmately 0.3% Organohalogen Halogen butyl rubber (tendency: Maximumcompounds decreasing) 0.1%

Rubber materials that can also be sorted based on characteristics of howthe rubber material was manufactured or the type of environment therubber material has been exposed to. For example, a heat-cured rubbermaterial may be sorted into a different group as a rubber material thatwas not heat-cured. As another example, a tire that has been exposed tohigh temperature fluctuations and/or UV exposure, such as in a desert,may be sorted differently from a tire that has been exposed to atemperate climate and/or low UV exposure. Alternatively, a rubbermaterial can be sorted based on its content of or exposure to toxic orhazardous materials, such as toxic radioactive materials, toxicchemicals, or hazardous waste compounds.

In an embodiment, an assessment process technique is based upon visualexamination of a rubber material, such as a tire or other materials, forselection and batching, be it using the human eye or other electronicsystem that recognizes the characteristic of the tire. For example,visual examination of a rubber material provide for informationregarding the manufacturer, manufacture date, or product model. Visualexamination can provide for a simplified method for sorting rubberproducts that have similar or substantially the same composition.Further analysis can be performed to identify the components of thesematerials that are identified as having similar or substantially thesame composition. In some embodiments of the invention, visualexamination is not required to identify the manufacturer, manufacturedate, or product model. This information can be obtained through othermethods, systems, and devices, including automated recognition,described herein. Knowledge of the manufacturer, manufacture date,and/or product model may be used to determine the composition, age,and/or other characteristics of the rubber products. Such informationmay be compared to and/or cross-referenced with other data in makingsaid determination.

In another embodiment, a process described herein can lead to electronicor automated recognition of different batches or end products. In someembodiments of the invention, automated systems utilizing optical,magnetic-based, and/or mechanical analysis can be used to characterize arubber material. For example, a rubber material can be examined using aspectrophotometric method that identifies one or more components of therubber material. Alternatively, a digital image of the rubber materialis obtained and processed to determine the manufacturer or informationregarding the rubber material.

FIG. 1 demonstrates assessment and selection procedures formanufacturing new products from recycled rubber. For example, old orused tires can be made available to the selection procedures under aquality control system. For example, the control system can be manualcontrol by trained professionals, or the control system can be automatedand under computer control. In an embodiment, a tire can beelectronically tagged or marked by an RFID, and then read by a computersystem for entrance in a selection procedure of the invention. After thesuitable redundant rubber is identified by a system (for example,trained personnel), it is batched and tagged for entry in a plantprocess, such as the plant process described herein. FIG. 1 alsodemonstrates a step of further assessing the rubber material in theselection procedures by type, size, or any other criteria relied upon asdetermined by the end use application. For example, the criteria may bedifferent for redundant rubber that will be used in part to manufacturea new tire as compared to redundant rubber that will be used at aplayground. In an embodiment, a recycled rubber end product of a processof the invention can be used to manufacture low-speed tires, such asfork-lift or bicycle tires. In another embodiment, a recycled rubber endproduct can be used as a source, in part, for the manufacture ofhigh-speed tires, such as automobile tires.

Material Sorting and Separation

FIG. 1 also demonstrates an exemplary process of transporting selectedmaterials into the plant for sample inspection. For example, a persontrained for inspecting the proper quality materials for an end useperforms the sample inspection. In an embodiment, a machine programmedto identify material based on criteria provided from a user performs thesample inspection. As shown in FIG. 1, after a material has beenselected to be processed, a preprocess procedure can be carried out. Forexample, preprocess procedures include extraction of metal beads,cutting of redundant rubber material, or other actions that may bedemanded by a certain end application, as would be obvious to oneskilled in the art. After the material is selected, and in anembodiment, prepared, it is processed through a plant, for example, asdescribed herein below. Material that has not been selected can also besorted and/or batched for alternative uses, or for preparation for anend application with different criteria. In another embodimentillustrated in FIG. 1, material extracted from the selected material,such as beads or metals, can be marked, sorted, and/or batched for otherindustrial processes. A facility for selecting a material can include aprovision for storage as illustrated in FIG. 1. In an embodiment, thestorage can correlate to time that is taken to transfer material priorto plant entry. For example, when the plant has to be decontaminated andcleaned of a previous batch throughput before a new material batchenters for process, material can be held in a secure storage area whererisks of mixing with other materials can be minimized by compliance withprocedures.

Material Size Reduction

An example rubber granule preparation plant is designed to process inexcess of 4 tons of in-feed tire of various defined quality compound perhour, including Auto, Commercial, and Truck tires to Super Singles Size15″ to 16″ wide and further cut sizes can be dimensioned to beaccommodated by the equipment for the process. The rubber granulepreparation plant may be designed to process any amount of infeed tires,including but not limited to amounts in excess of 1 ton, 2 tons, 3 tons,4 tons, 5 tons, 6 tons, 8 tons, 10 tons, 12 tons, 15 tons, 20 tons, 25tons, 30 tons, 50 tons or more, and/or up to 1 ton, 2 tons, 3 tons, 4tons, 5 tons, 6 tons, 8 tons, 10 tons, 12 tons, 15 tons, 20 tons, 25tons, 30 tons, 50 tons or less. A finished product size can be dependentupon final granulation grid hole diameter based upon a sizing table; forexample, a supplied basic finished product granules are about ⅘ mm. Insome embodiments of the invention, the finished product granules are upto about, greater than about, or about 0.01, 0.1, 0.5, 0.8, 1, 2, 4, 5,10, 20, or 50 mm in size. The finished product can have a size that isbetween about 0.5 to 10 mm, 1 to 7 mm, 3 to 6 mm, or 4 to 5 mm.

During a process described herein for producing a redundant rubberproduct, waste or used rubber can be fed into a system or device fortearing, shearing, or shredding the waste material. In an exemplaryembodiment, tires are fed into a rotary shear hopper. Other types ofdevices for shredding redundant or recycled rubber may vary to achievesize shape and density for process requirements because the granulate orpowder products are designed for an end use application.

In an example, the rotary shear consists of two slow speed contrarotating shafts fitted with hook type knives interspaced with protectivediscs. Individual hydraulic motors, each fitted with a reductiongearbox, can drive the shafts. All bearings are oil filled and themachine and cases are sealed to avoid ingress of deleterious liquids.The hydraulic motors are provided with hydraulic oil from a separateself-contained power pack, complete with oil cooler and electricalcontrols. The unit is mounted on a self-supporting steel structurecomplete with in-feed hopper and discharge chute.

After the processed material leaves system or device for tearing,shearing, or shredding the waste material, the processed material can bedischarged by means of a conveyor. In an example, the conveyor is arubber chevron belt conveyor. The conveyor can be any conveyor or systemas would be obvious to one skilled in the art to move processed materialfrom one part of the process to the next. Alternatively, any processedmaterial may be moved manually.

In an embodiment, at the head of the conveyor, processed material isdivided and directed onto two conveyors that carry the processedmaterial onto at least one preshredder. A first stage preshredder can befitted with grids having a hole size of about 50 mm in diameter, and therotor of the preshredder may run at a known and predetermined speedwhich may materially affect the quality of the end products. In someembodiments, the rotor of the pre shredder may be running at a ratefalling within 10-300 rpm, 50-200 rpm, 90-150 rpm, or at about 10 rpm,30 rpm, 50 rpm, 80 rpm, 90 rpm, 100 rpm, 120 rpm, 140 rpm, 150 rpm, 170rpm, 180 rpm, 190 rpm, 200 rpm, 210 rpm, 220 rpm, 230 rpm, 250 rpm, 270rpm, 290 rpm, 300 rpm, 350 rpm, or at any other speed. The predeterminedspeed may depend on the material being shredded and/or desiredcharacteristics of the end product. The preshredder rotor speed mayaffect the shape of the resulting shredded material. In someembodiments, a slower rotation may provide more torque which can copewith a choked feed. This may improve the shape of the product. The feedspeed and the rotational speed, together with the amount of feedstockmay determine the characteristics of the finished product. In someembodiments, a more cubic finished product may be preferable. In otherembodiments of the invention, the grids can have a hole size of up toabout, greater than about, or about 10, 20, 50, 75, 100, or 150 mm indiameter. The preshredder may also be run at up to about, about, orgreater than about 50, 150, 200, 250, 300, or 350 rpm.

The materials upstream of the preshredder may be continually monitoredto ensure that both feeding and processing are matched. The feeding andprocessing speeds may be coordinated to produce desired characteristics(e.g., compositions, shapes) of an end product.

In an embodiment, a preshredder comprises a rotator with knives in achevron formation rotating on a steel body. In the exemplary embodiment,the body can be fitted with two rows of static adjustable knives and, inhigh wear areas, with a wear resistance liner. In another embodiment,the first stage preshredder is fitted with a grid having a hole size ofabout 10-500 mm in diameter. The grid can also have a hole size that isup to about, about, or greater than about 1, 5, 10, 50, 75, 100, 200,300, 400, 500, 750, or 1000 mm in diameter. The hole size can be betweenabout 1 to 1000, 5 to 750, 10 to 500, 20 to 250, or 40 to 125 mm. A gridcan be easily removable, such as with a hydraulic lowering device. Inyet another embodiment, a rotor of the preshredder can run at a knownand predetermined speed. In some examples, this known and predeterminedspeed may fall between about 10-1000, 20-750, or 50-400 rpm, or may haveany other speed. Material is discharged from the grid at the bottom ofthe machine and can be carried away by a vibrating conveyor. Thevibrating conveyor is often composed of metal and therefore, canaccommodate any heated steel components that may be present in theprocessed material without damage to a system of the invention. Thevibrating conveyor can also create a proportionate reduction in firerisk. In another embodiment, a mist spraying system is fitted to thepreshredder to reduce friction, thereby improving cutting and reducingfire risk. In this example, the water flow can be controlled to obviatewet finished product and filtration can be used to control dustemission.

In an embodiment, shredded material discharged from the first stagepreshredder along the vibrating conveyor can be elevated by means of aconveyor to a second stage preshredder with a grid size having holes ofa smaller diameter than the grid fitted on the first stage preshredder.For example, a grid fitted on a second stage preshredder can have holes10-500 mm in diameter. The grid can also have a hole size that is up toabout, about, or greater than about 1, 5, 10, 50, 75, 100, 200, 300,400, 500, 750, or 1000 mm in diameter. The hole size can be betweenabout 1 to 1000, 5 to 750, 10 to 500, 20 to 250, or 40 to 125 mm. In yetanother embodiment, a rotor of the second stage preshredder can run at aknown and predetermined speed. In some instances, the known andpredetermined speed may fall between about 10-1000, 20-750, or 50-400rpm, or at any other speed.

The second stage preshredder can consist of a higher speed-rotatingshaft fitted with knives. The second stage preshredder can producematerial of less than about, about, or greater than about 0.5, 1, 5, 10,20, 30, 50, 75, 100 or 150 mm in size. After shredding the processedmaterial in the second stage preshredder, the material can exit thepreshredder and onto another conveyor. In an embodiment, material exitsthe second stage preshredder onto a metal belt-shaking conveyor. Aspraying system can be fitted to the shredder to reduce friction,improving cutting and reducing fire risk. In a further embodiment, waterflow is controlled to obviate wet finished product.

The processed material after traveling through at least one preshreddercan then be fed onto a conveyor. Preferably, the processed material is agranule of about 1000-1, 500-5, or 100-10 mm diameter or less. In anembodiment, the conveyor is a rubber belt conveyor fitted with eccentricrollers beneath the belt to agitate the material and thus maximize steelremoval by means of a magnetic table. The processed material granulescan then be transferred to another conveyor, for example, a rubberbelt-elevating conveyor. In an embodiment, the magnetic table is anoverband magnetic unit suspended from a steel frame above the conveyorto remove any steel material from the processed rubber material.

Magnetic Separation

After shredding, the processed material can be delivered to a storagehopper that controls the feed rate onto a further conveyor. In anembodiment, the conveyor is a chevroned, rubber belt, elevatingconveyor. In an embodiment, the storage hopper is a fabricated steelstructure that is flexibly mounted to reduce wear. The storage hoppercan include an adjustable gate to control the flow of material.

The processed material can then be fed to a granulator section thatcomprises initially of a recovery granulator fitted with grids havingabout 12 mm diameter holes. The holes can also be less than about,about, or greater than about 1, 2, 4, 6, 8, 10, 15, 20, 25, 50, 75, or100 mm in diameter. The granulator section typically comprises anin-feed hopper and under grid vibrating conveyor to remove thegranulated rubber. An overband magnet is mounted over the vibrating trayto remove steel particles. The rubber granules fall from the end of thevibrator directly into the bucket elevator. Filtration takes place inthe same manner as on the preshredders.

In an embodiment, the processed material after the granulator section isabout 95% metal-free. In another embodiment, the processed material isabout 99% metal-free. In yet another embodiment, the processed materialcontains no metal material. In an embodiment, the processed materialafter the granulator section is about 95% free of magnetic material. Inanother embodiment, the processed material is about 99% free of magneticmaterial. In yet another embodiment, the processed material contains nometal material. In an embodiment, the processed material after thegranulator section is about 95% steel-free. In another embodiment, theprocessed material is about 99% steel-free. In yet another embodiment,the processed material contains no steel material. The percent that theprocessed material is free of a given type of material can be determinedon a mass basis, volume basis, or a combination thereof.

Additional Processing

In an embodiment, the bucket elevator conveyor elevates material anddischarges it into the top of a zigzag system, which is via a rotaryvalve system. The zigzag conveyor allows any heavy material, such asrocks or metal valves, to be discharged from the bottom. A furtherprocessed material can be drawn from the top by means of a pneumaticconveyor system into a cyclone which may be unique in that the velocityand quantity of air flow can be adjusted remotely, which may materiallyaffect the quality of the finished product, where it is discharged intoa screw-elevating conveyor, which feeds the final system. The airflowvelocity may fall within the range of 5 m/s to 300 m/s, 15 m/s to 200m/s, or about 22 m/s to 100 m/s. The airflow velocity may have anyvalue, which may include those of 2 m/s, 5 m/s, 10 m/s, 15 m/s, 20 m/s,22 m/s, 25 m/s, 30 m/s, 40 m/s, 50 m/s, 70 m/s. 90 m/s, 100 m/s, 120m/s, 150 m/s, 200 m/s, 250 m/s, 300 m/s, 500 m/s or greater or lower.The airflow velocity may depend on the material being processed.

The second stage granulator is a similar machine to the previousgranulator, but can be fitted with a grid having about a 5 mm diameterhole size. The grid can have hole sizes that are less than about, about,or greater than about 0.01, 0.1, 0.5, 1, 2, 4, 7.5, 10, 15, or 20 mm indiameter. The second stage granulator can be filtered as the firststage. Material from the granulator, after removal by the metalvibrating conveyor is elevated by means of a screw conveyor and fed to aclassifier, wherein any fluff, sterile and light materials is removed byair and transported to the filtering system. The classifier may beinnovative in that the input and output speeds can be controlledremotely, and may materially affect the quality of the finished product.The classifier may run in tandem with the cyclones, and the balancedoperation of both may provide desired characteristics for the endproducts. The processed material, now rubber granules, are sized byvibrating trays, and the sized products are elevated by screw conveyorsfeeding permanent rotary magnets to remove any remaining steel. Thefinal rubber products will be passed to the storage system by elevatingscrew conveyors.

In some embodiments of the invention, a rubber material can be subjectedto devulcanization. Devulcanization can include any devulcanizationmethod known to one skilled in the art, including methods that involvechemical or physical processing, or methods described in “Evaluation ofWaste Tire Devulcanization Technologies”, CalRecovery Inc., CaliforniaIntegrated Waste Management Publication, December 2004, incorporatedherein by reference in its entirety. For example, a devulcanizationprocess can include pyrolyzing the rubber, subjecting the rubber tocryogenic conditions, or subjecting the rubber to ultrasonic waves ormicrowaves.

Product Packaging

In some embodiments of the invention, the processed rubber is packagedfor delivery to a user. The processed or recycled rubber can beaccompanied by a product specification or specification sheet thatincludes information regarding one or more of the following: particlesize, composition, metal content, mechanical properties, sourcematerial, source material composition, and source material mechanicalproperties. The packaged products may or may not be identified withtraceable tags or other devices. In some instances, information that wasassociated with and/or stored in traceable tags may be used informulating the product specification. The products can be standardizedin accordance with any regulatory guidelines, including ISO standards.Packaged products can be inspected for quality control to ensure productquality and/or composition.

Controls

FIG. 2 illustrates a high-level depiction of a controlled processingsystem in accordance with an embodiment of the invention. The system mayinclude a processing arrangement that may include or more processingequipment. The processing arrangement may include sorting equipment,shredding equipment, separating equipment, granulating equipment, andblending equipment that may correspond to one or more sorting step,shredding step, separating step, granulating step, and blending step ina process for recycling rubber. A controller may be in communicationwith one or more processing equipment of the processing arrangement. Theprocessing equipment may be variable and programmable.

In one example, a controller may be configured to communicate with atleast one of the following: sorting equipment, shredding equipment,separating equipment, granulating equipment, and blending equipment. Insome instances, the controller may communicate with one, two, three,more, or all of the aforementioned types of equipment. The controllermay send one or more signal to the associated equipment, therebyaffecting an operating parameter of the associated equipment. Forinstance, the controller may control the speed of a preshredder rotor.In another example, the controller may control the speed of a conveyor.In yet another example, the controller may control the airflow speed ina cyclone. The controller may control any operating parameter within aprocessing arrangement, which may include but is not limited to: speedof operation, speed of rotation, speed of conveyance, time,temperatures, strength, treatment chemicals, and/or any other operatingparameter.

In some embodiments, the controller may also receive communications fromthe associated equipment. For example, feedback configurations may beprovided where a controller may receive information from the associatedequipment and adjust the performance of the associated equipmentaccordingly.

The controller may communicate with the associated equipment viaelectrical signals. In some instances, the controller may communicatewith the associated equipment via wired or wireless communications.

In some embodiments, the controller may be provided at a control center.The control center may preferably be onsite with the rest of theprocessing arrangement. In other embodiments, the control center may beremote to the rest of the processing arrangement. The controller mayinclude one or more computer system and/or microprocessors. Thecontroller may include tangible computer readable media with logic,code, data, instructions, may be used to implement any software, steps,processes or methodology.

The controller may be configured to interface with one or more user. Theuser may or may not be trained personnel as described elsewhere herein.The controller may receive an input from the user. The input may includebut is not limited to input relating to sorting, materialcharacteristics, material identification, identification orcharacteristics of desired end products, or processing equipmentperformance characteristics. The input may be received via a userinteractive interface. In some instances, the user interactive interfacemay also display information to the user. In response to the displayedinformation, the user may or may not choose to provide or adjust aninput. In some instances, the controller may operate independently of auser. For example, the process may operate autonomously from a user. Thecontroller may continuously or spot-monitor the operation of theprocessing equipment. In some instances, only occasional userintervention may occur.

A processing arrangement may include a sorting assembly that may enablean associated sorting step in a process. The sorting assembly mayinclude devices that may allow raw material to be sorted according toraw material characteristics. For example, the raw material may be awaste rubber. The waste rubber may be sorted according to composition.Such equipment that may enable such sorting may include but is notlimited to rotary shear, a troughed out feed conveyor, and/or a dividingchute and conveyor. In some embodiments, the sorting equipment mayoperate similarly to a luggage carousel. The sorting equipment may havea circular, or any other shape.

The raw material may be optically scanned (or may use any otherrecognition technique) to identify the raw material. For example, anoptical scanner may receive an image of a rubber tire, and employalgorithms to visually analyze the tire to determine a manufacturer,model number, or any other identification information for the tire. Insome instances, the model or other identifying number may be visible onthe tire image, and may be determined using the optical scanning system.In other instances, the images may be viewed by personnel to identifythe tire. In other embodiments, physical features of the tire, such asthe size, tread, shape, magnetic properties, material properties,weight, may be analyzed to identify the tire. Alternatively, the tiresmay be pre-sorted or pre-tagged with a tire identifier. Any othersensors may be utilized to assist with identifying the tire. In someembodiments, the controller may be communicating with the scanner,sensors, or other identification means.

Based on the tire identification (or identification of any other rubberproduct), one or more database or set of records may be accessed. Adatabase may include additional information relating to an identifiedtire (or other rubber product). Such additional information may include(but is not limited to) material composition, metal content, mechanicalproperties, age, other material properties, and/or information relatingto processing equipment operating parameters for a given end product.The additional information may be associated with the rubber productidentity. Based on this additional information, the tires/rubberproducts may be sorted using the sorting equipment, so that materialswith the same or similar material properties may be sorted into the samecontainers and/or processing line. Alternatively, the material need nothave the same composition, but may have other desirable characteristicsthat may allow it to be provided to the same processing line. Thecontroller may keep track of what materials are sorted for which processto yield a desired end product. The controller may also control whichmaterials are sorted into which process.

A processing arrangement may include a shredding assembly that mayenable an associated shredding step in a process. The shredding assemblymay include devices that may allow sorted material to be shredded todesired size, shape, and/or other characteristics. In some instances,the sorted material may have similar compositions, or fall within adesired composition range. The shredding assembly may include but is notlimited to a pre-shredder feed conveyor, a pre-shredder, a troughedtransfer conveyor, and another pre-shredder. In some instances, one,two, three, four, or more shredding steps may be employed. Any of theshredding equipment of the shredding assembly may be in communicationwith the controller. The controller may determine the rotor speed of apre-shredder and/or the speed of a conveyor. The controller maycoordinate and/or control the conveyance speed and/or rotor speed toyield a desired material property (e.g., shape, size) of shreddedmaterial. This may affect the desired material property of the endproduct, down the line.

In some implementations, the processing arrangement may include aseparating assembly which may enable an associated separation step in aprocess. The separation assembly may include one or more devices thatmay separate out certain materials. In some instances, the separationassembly may remove metals (e.g., steel), or other materials, which mayinclude toxic materials. The separating assembly may include but is notlimited to a magnetic table, troughed steel discharge conveyor, troughedtransfer conveyor, and/or an overband magnet. Magnets may be used toremove metal components. Other treatments including mechanicalseparation, or chemical separation may be utilized to separate certainmaterials. A prime material may continue along the process to thedesired end product. The removed material may be stored, disposed of, orused for different processes. The controller may communicate with any ofthe separating equipment. For example, the controller may control theconveyance speed and/or control the strength of one or more magnet. Suchcontrols may determine how much of the material is separated.

A granulating step may follow a separating step. The processingarrangement may include a granulating assembly which may be associatedwith the granulating step in the process. The granulating assembly mayinclude one or more devices that may assist with further cutting orgranulating the material. This may result in improving the shape of thematerial. The granulating assembly may include devices such as atroughed transfer conveyor and one or more recovery granulator. Thecontroller may be communicating with any of the granulating equipment inthe granulating assembly. The controller may determine the rotor speedof a recovery granulator and/or the speed of a conveyor. The controllermay coordinate and/or control the conveyance speed and/or rotor speed toyield a desired material property (e.g., shape, size) of granulatedmaterial. This may affect the desired material property of the endproduct, down the line.

The processing arrangement may include a blending assembly which may beassociated with a blending step in the process. The blending assemblymay include blending equipment that may further refine the desiredmaterial property (e.g., size, shape). The blending assembly may includebucket elevating conveyor, zig zag, cyclone, screw elevating conveyor,and/or selecting table. The controller may be communicating with any ofthe blending equipment. The controller may determine the air flow speedof a cyclone and/or the speed of a conveyor. The controller maycoordinate and/or control the conveyance speed and/or cycle air speed toyield a desired material property (e.g., size, shape) of blendedmaterial. This may affect the desired material property of the endproduct.

In some embodiments, throughout the process, the controller may keeptrack of the material identity for the batch being processed. In someinstances, batch processes or continual processes may be utilized. Thecontroller may continuously monitor the materials throughout theprocess. The controller may communicate with sensors that may performspot-checks of the material throughout the process to perform qualitycontrol. The sensors may be provided at one or more of the processingdevices at any point along the rubber recycling process. In someembodiments, the controller need not communicate with every assembly inprocessing arrangement, and may selectively communicate with particulardevices and/or sensors.

In some embodiments, the end product may be packaged as describedelsewhere herein. The controller may be communicating with the packagingsystem, and may be utilized in generating a product specification forthe packaged end product material.

The controller may cause any of the apparatuses described to operate ina manner to yield a desired end product. In some instances, thecontroller may utilize an algorithm or determine how particular piecesof equipment should operate given the raw materials and/or the desiredend products. In other embodiments, look-up tables or records may beprovided that may provide specifications for equipment operations giventhe raw materials and/or the desired end products. Feedback systems mayor may not be utilized.

Any of the assemblies and/or steps described herein may occur in anyorder. For example, they may occur in the sequence that they aredescribed. They may also occur in any other sequence (e.g., granulatingmay occur before separation, etc.). In some instances, components of thevarious assemblies described may or may not be provided before or aftercomponents of other assemblies so that the steps may be intermixed. Forexample, a separating step may occur, then a granulating step, thenanother separating step, then another granulating step and/or blendingstep. Any of the steps described herein may also be optional and similarsteps and/or assemblies may be substituted for any of the steps orassemblies described herein.

Systems

The various units of the processing system can be provided by a varietyof manufacturers, including MTB Recycling, Trept, France and EngineeringServices (Bridgend) Limited, Bridgend, United Kingdom. The system, asdescribed, above can be controlled from two control stations and relaypanels, fitted with stop and start buttons and other metering devices.The various units can be electrically interlocked to ensure the plant isstarted in an orderly manner and is closed down in an orderly manner inthe event of emergency.

The various units of the system can also include shear feed conveyors,splitter feed conveyors, steel outfeed conveyors, screw feed conveyor,drum separator screw feed conveyors, drum separators, air-cleaningsystems, and electrical cabinets. A shear feed conveyor can be used tomove materials to a shearing unit. A steel outfeed conveyor can be usedto transport steel away from processing unit. Drum separators can beused for magnetic separations, or any other type of separation.

The systems described herein can include an air-cleaning system forremoving materials from the air. The air-cleaning system can reduce theamount of particulates in the air and/or reduce the chance ofspontaneous combustion or other hazardous conditions.

In some embodiments of the invention, the processing units and becleaned between groups or batches of material such that the productsfrom each group or batch are substantially free of products from anothergroup or batch. Cleaning between groups can improve product quality andreduce the chance of undesired components being present in the product.Cleaning can include washing, gas-blowing, manual cleaning, chemicalwashing, air-cleaning, replacement of parts, substitution of parts,switching of processing units, or any combination thereof.

Example 1

FIGS. 3A, 3B, 3C, and 3D demonstrate an exemplary system as describedherein. After raw material, such as waste or redundant rubber, isselected by a process, such as a process of the invention carried out bytrained personnel or automated system (e.g., optical scanning), thespecified raw material is delivered and loaded for a first shreddingprocess. A rotary shear can initiate the shredding process by specifiedsize of material, such as a tire. In one example, the rotary shear maybe a model 175 H.P. machine, which may have a heavy-steel body which maybe fitted with 2 slow speed contra rotating shafts. The shafts may befitted with hook knives, interspaced with protective discs. The shaftsmay be driven by individual hydraulic motors, each fitted with areduction gearbox. The bearings may be oil filled and the machine andcases may be sealed to avoid ingress of deleterious liquids. The machinemay be mounted on a fabricated steel support structure with accessladder, and may be fitted with a fabricated in-feed hopper and dischargechute. Hydraulic motors may be provided with hydraulic oil from aseparate self-contained power pack, which may be complete with oilcooler and electrical controls. The motor may be a 130 kW, 415 V, 50 Hzmotor and the knives may be 120 mm 2 hook knives. Any other rotary shearwith any other specifications or configurations may be utilized.

The shredded material is then transported by a troughed out feedconveyor and divided by a dividing chute and conveyor, from which thedivided material is transported by a preshredder feed conveyor byspecified shred sizes. The specified size shredded processed rubbermaterial is reduced by a first preshredder wherein a size of shreddedmaterial can be chosen or programmed by a user. In one implementation,the troughed out feed conveyor may be fitted with a rubber chevron beltto elevate product from rotary shear to the dividing chute and may befitted with steel supporting legs. The width of the conveyor may beabout 900 mm, the drum centers may be 5 m, and the motor may be a 6 kWmotor. In some examples, the dividing chute and conveyor may include achute that divides and transfers shred to dividing conveyors, and thenonwards to shredder feed conveyors. The dividing chute and conveyor mayhave a width of 800 mm, the drum centers may be 5 m, and the motor maybe a 3 kW motor. In accordance with some embodiments, the preshredderfeed conveyor may be a rubber chevron belt conveyor to elevate the shredto the preshredder. The width of the conveyor be about 800 mm, the drumcenters may be 6 m, and the motor may be a 3 kW motor. Any otherconveyors with any other measurements or configurations may be utilized.The first preshredder may be a machine with a heavy-duty rotator fittedwith knives in a chevron formation rotating on a heavy fabricated body.The body may be fitted with two rows of static adjustable knives andinternally lined in high wear areas with wear resistance liner plates.The shaft may be supported in heavy duty bearing grease lubricated froma central point. In addition, two mist spray units may be fitted to cooland lubricate the knives and blades of the machine. The grids may beeasily removable and the machine may be fitted with a specialhydraulically operated lowering device to facilitate removal. Themachine may be belt driven from an electric motor and may be fitted witha protective clutch against overload condition. The shredder product maybe removed via a steel-vibrating conveyor. The opening size may be about2150 mm×900 mm. The grid holes may be 50 mm in diameter. The rotor speedmay be about 190 rpm. The motor may operate at 132 kW at 1000 rpm. Anyof operating conditions and/or specifications relating to thepreshredder are provided by way of example only, and any otherpreshredder may be used.

The process material is then transported by a troughed transfer conveyorto another preshredder that further shreds the rubber material to aprogrammed size, which is then moved by a vibrating conveyor with amagnetic table for the removal of steel particles. In one example, thetroughed transfer conveyor may be fitted with a rubber chevron belttransfer material to conveyor preshredder. The width of the conveyor maybe about 600 mm, the drum centers may be 5 mm, and the motor may be a 2kW 415 V 50 Hz motor. Any other conveyor with any other specificationsor measurements may be used. The second preshredder may be a machinewith a heavy-duty rotator fitted with knives in a chevron formationrotating on a heavy fabricated steel body. The body may be fitted withtwo rows of static adjustable knives and internally lined in high wearareas with wear resistance liner plates. The shaft may be supported inheavy duty bearing grease lubricated from a central point. The grids maybe easily removable and the machine may be fitted with a specialhydraulically operated lowering device to facilitate removal. Themachine may be belt driven from an electric motor and may be fitted witha protective clutch against overload condition. The shredded product maybe removed via a steel-vibrating conveyor. The opening size may be about1200 mm×450 mm. The grid holes may be 30 mm in diameter. The rotor speedmay be about 395 rpm. The motor may operate at 132 kW at 1000 rpm 415 V50 Hz. Any of operating conditions and/or specifications relating to thepreshredder are provided by way of example only, and any otherpreshredder may be used. The magnetic table may operate so that thematerial, now under 30 mm from the out feed conveyor is carried on arubber belt vibrating conveyor. Agitation may be achieved by powerdriven eccentric rubber covered wheels mounted below the top belt. Anoverband magnet may be suspended from a steel frame above the rubberbelt and may carry off steel particles from the product. Plates likelyto be affected by the magnets may be supplied in non-magnetic steel. Thebelt width may be about 800 mm, the drum centers may be about 2000 mm,and the total power may be about 5 kW, 415 V, 50 Hz. Any other magnetictable dimensions or configurations, or magnetic separation techniquesmay be utilized.

As demonstrated in FIGS. 3A, 3B, 3C, and 3D, after the magnetic table,the steel particles removed from the rubber can then be transported by atroughed steel discharge conveyor to an area where a decision to recycleor select the metal for alternative process can be made. The “most metalfree” processed rubber material can be an end product for sale and go byanother conveyor to a storage hopper for packing and customer delivery.The troughed steel discharge conveyor may be fitted with a chevron beltto transfer material to dump. The troughed transfer conveyor may befitted with a chevron belt to transfer material to the storage hopper.The conveyor width may be about 600 mm, the drum centers may be 5 m, andthe motor may be a 2 kW, 415 V, 50 Hz motor. The storage hopper may be afabricated steel structure flexible mounted in a frame to reduce wearand jamming. The design may incorporate steep sides and an extra-widesteel belt to dramatically reduce bridging and obviate the necessity offitting special anti-bridging devices. An adjustable gate may controlthe flow and the metal belt out-feed conveyor may be automaticallycontrolled from the shredder to provide smooth loading and optimize theperformance of the downstream equipment. The hopper size may be about2900 mm×1390 mm. The outfeed conveyor may be about 800 mm wide×3250 mm.The motor may operate at 3 kW, 415 V, and 50 Hz. Any of these devicesprovided herein are provided by way of example only, and any othercomparable devices or devices with varying dimensions or characteristicsmay be utilized.

As shown in FIGS. 3A, 3B, 3C, and 3D, the processed rubber material canalso go forward by a conveyor from the process as described or from astorage hopper. The conveyor may be a troughed transfer conveyor fittedwith a chevron belt to transfer material to a recovery granulator. Theconveyor may have a belt width of 600 mm, a drum center of 5000 mm, anda 2 kW, 415 V, 50 Hz motor. Any other conveyor with any other featuresor configurations may be used.

Personnel can then make a decision on the final shape or size of the endproduct material sent to the recovery granulator. The shape or size canbe filtered by a grid with used defined specifications. Once the productgoes through the recovery granulator, the processed material can passthrough an overband magnet for the removal of any additional metal(e.g., steel) in the material. Once through the overband magnet, thebucket conveyor elevates the processed material to the entrance hopperfor a Zigzag conveyor as shown in FIGS. 3A, 3B, 3C, and 3D. In someimplementations, the recovery granulator may have an opening size of1000 mm×300 mm with a grid hole size of 12 mm in diameter. The rotorspeed may be about 540 rpm, and the motor may operate at 110 kW, 1500rpm, 415 V, and 50 Hz. The bucket conveyor may elevate material to theentrance hopper on the zigzag by means of rubber bucks and may be chaindriven. The conveyor may have a discharge height of about 3340 mm, andthe motor may be a 2 kW, 415 V, and 50 Hz motor. Apparatuses ofdifferent dimensions or specifications may be used.

The material is pneumatically fed from the integral hopper into theZigzag at the top. Heavy components continue down the Zigzag forcollection and removal for further process or alternative recycling.Rubber granules from the Zigzag are separated in the cyclone anddischarged to a screw conveyor to feed into the recovery granulator.Dust removal can be controlled through the Top Hat of the cyclone byfiltration. A bin or conveyor for further processes or alternativerecycling can remove heavy components. In accordance with one example,the material may be fed via a rotary valve into the zigzag, which may beconstructed in steel. Rubber may be discharged via the top pneumaticallyand heavy components, valves, etc. may continue down the zigzag to bedischarged at the base into a customer's bin. Rubber granules from thezigzag may be separated in the cyclone and discharged via a rotary valveto a screw conveyor. Air and dust may be removed from the top hat of thecyclone and may feed to the filter. The rotary valve motor may operateat 0.75 kW while the fan motor may operate at 7.5 kW. Suchconfigurations are provided by way of example only.

Programmed material is discharged from the cyclone to the second seriesgranulator by a screw elevator. The screw elevator can deliver theprogrammed material to the final recovery granulator for granulation tothe specified end product dimension regulated by the appropriate gridsizes installed in the granulator according to the end product required.The screw elevator may utilize a 22 kW, 415 V, 50 Hz motor. In someimplementations, the recovery granulator may having an opening size of1000 mm×330 mm and a grid hole size with a 5 mm diameter. The rotorspeed may be about 540 rpm, and the motor may operate at 110 kW, 1500rpm, 415 V, and 50 Hz.

Programmed material is elevated away from the granulator and dischargedonto the selecting table using the screw elevator conveyor. The screwelevating conveyor may optionally have a discharge height of 2500 mm anda 2.2 kW, 415 V, 50 Hz motor. Fiber and dust are removed from theproduct on the selecting table and the processed is finally sized usingvibrating sieves pre-set to the end product specification. At theselecting table, screw elevator conveyors to pass over the magneticseparator for a final steel check and removal transfer the material. Theselecting table machine may remove fiber and dust, and may size crumbsinto two (or more) streams by vibrating sieves. About 25 kW in power maybe used. In one case, the screw elevating conveyor may utilize a 2.2 kW415 V 50 Hz motor.

End product produced and finally checked through the magnetic separatoris conveyed away from the separator by a screw elevating conveyor to bepacked and enter finished stock control. The magnetic separator may beusing 5 kW of power. Optionally, the screw elevating conveyor mayutilize a 2.2 kW 415 V 50 Hz motor.

In some embodiments, after the material has gone through the selectingtable and an end product is produced, if further blending is determinedto be required, it may be transferred to a selecting table once more viaa screw elevating conveyor. The selecting table machine may again removefiber and dust. This may be repeated until it is determined that thematerial has been sufficiently blended. If further blending is notrequired, then the end product may be packaged.

The supply may include air ducting, hoods and filtration on thepre-shredder, shredder, granulators and/or selecting table. Five units,each of 5.5 kW power consumption may be provided and sited adjacent tothe equipment requiring air cleaning. The filter bags may be vibrated toavoid dust clogging the filter. The total power used may be about 27.5kW.

Unsuitable material for specified end product use is removed by theseparator and is transported away by bin or conveyor for further processor alternative use.

After the end product has been processed by the exemplary method,trained personnel or computer systems can perform stock control forinspection labeling and delivery processes. The details of end productsand traceability details can be recorded. Full information can beprovided to a customer, for example, on invoices. In addition, thesystems also provide ISO standard particulars to customers.

Starting and electrical control of the equipment may be from one, two,or more centrally located control stations, per line, fitted withstart/stop buttons, ammeters, or other controls. The starting andstopping sequences of the equipment may be interlocked to ensure thataccidental stoppage of one item of equipment may give an orderly andsequential stoppage of all items on the production line. In addition,emergency stop buttons may be located strategically about the plant toensure safety of the operators.

While preferred embodiments of the present invention have been shown anddescribed herein, it will be obvious to those skilled in the art thatsuch embodiments are provided by way of example only. Numerousvariations, changes, and substitutions will now occur to those skilledin the art without departing from the invention. It should be understoodthat various alternatives to the embodiments of the invention describedherein may be employed in practicing the invention. It is intended thatthe following claims define the scope of the invention and that methodsand structures within the scope of these claims and their equivalents becovered thereby.

1. A system for recycling tire rubber material comprising: a. aselection system for inputting a selection of a desired end producthaving a selected chemical composition by a user, and based on saidselection determines criteria for generating rubber granules for themanufacture of the desired end product selected by the user, wherein thecriteria includes the selected chemical composition; b. at least oneshredding device for shredding waste tire rubber material, wherein saidat least one shredding device is fitted with a grid that determines thesize of the shredded material; c. at least one conveyor for transportingthe shredded material through the system; and d. at least one metalremover, wherein said at least one metal remover removes metal from theshredded material, wherein the system generates rubber granules of apredetermined size having the selected chemical composition based uponsaid desired end product selected by a user.
 2. The system of claim 1,wherein the criteria for rubber granules includes granules of betweenabout 4 to 5 mm.
 3. The system of claim 1, wherein the rubber granulesare about 95% metal-free.
 4. The system of claim 1, wherein the rubbergranules are about 99% metal-free.
 5. A process for recycling wasterubber-based material for a desired end product comprising: a. trainingpersonnel for identification of a chemical composition of wasterubber-based material; b. selecting the desired end product having aselected chemical composition c. determining a desired chemicalcomposition of the waste rubber-based material based on the end productand the selected chemical composition; d. identifying the chemicalcomposition of the waste rubber-based material, wherein said identifyingis carried out by said personnel; and e. separating said wasterubber-based material based upon whether the identified chemicalcomposition of the waste rubber-based material is the desired chemicalcomposition, thereby generating the end product having the selectedchemical composition; f. delivering the end product to a user.
 6. Theprocess of claim 5, wherein the waste rubber material is tagged withidentifying information.
 7. The process of claim 5, wherein theseparating step comprises separating based on magnetic properties. 8.The process of claim 5, wherein the separating step comprises separatingbased on density.
 9. The process of claim 5, wherein the recycled rubberis accompanied by a specification sheet that contains informationregarding the recycled rubber.
 10. A process for recycling rubbercomprising: a. selecting recycled rubber-based material(s) formanufacture, having a selected chemical composition; b. assessing aplurality of waste rubber-based materials according to a chemicalcomposition of the waste rubber-based materials; c. selecting at leastone of said waste rubber-based materials for processing of the chemicalcomposition as assessed in step b), wherein the selected wasterubber-based material(s) are selected for the manufacture of theselected recycled rubber-based material(s) having the selected chemicalcomposition; d. separating the selected waste rubber-based material(s)of step c); and e. processing said separated waste rubber-basedmaterial(s) into material for said manufacture of said selected recycledrubber-based material(s) having the selected chemical composition. 11.The process of claim 10, wherein the assessing of waste rubber materialsincludes analyzing the chemical composition of the waste rubbermaterials.
 12. The process of claim 10, wherein the separating stepincludes removing toxic materials.
 13. The process of claim 10, whereinthe separating step includes removing metals.